Reduced solar absorptivity applique

ABSTRACT

A reduced solar aborptivity appliqué having a surface layer for adhering to an surface and high aspect ratio microstructures extending from the surface layer having pigmentation or spectral tailoring.

REFERENCE TO RELATED APPLICATIONS

This application is copending with U.S. patent application Ser. No.12/361,840 entitled Rigid Tipped Riblets by inventors Diane C. Rawlingsand Kevin R. Malone, U.S. patent application Ser. No. 12/361,882entitled Shape Memory Riblets by inventors Diane C. Rawlings and TerryL. Schneider, U.S. patent application Ser. No. 12/361,918 entitledAmorphous Metal Riblets by inventors Diane C. Rawlings and StephenChristensen all filed on Jan. 29, 2009, U.S. patent application Ser. No.12/566,927 filed on Sep. 25, 2009 entitled Elastomeric Riblets byinventors Diane C. Rawlings and Alan Burg and U.S. patent applicationSer. No. 12/566,907 filed on Sep. 25, 2009 entitled StructurallyDesigned Aerodynamic Riblets by inventors Diane C. Rawlings, McLean andMary J. Mathews, the disclosures of which are incorporated herein byreference.

BACKGROUND INFORMATION

1. Field

Embodiments of the disclosure relate generally to the field of reductionof solar absorptivity in surfaces and more particularly to embodimentsand fabrication methods for use of riblets or other high-aspect-ratio(height to base) surface microstructures having coloring and spectraltailoring for reduced solar absorptivity extending from a base layer.

2. Background

Strength and durability of composite structures may be impacted byexcessive heating due to effects of solar absorptivity of the surface ofthe structure or coatings applied to the surface due to color orspectral properties. Reducing solar absorptivity of the exteriorsurface/paint/appliqué is an approach to reduce the solar heating issue.Use of low solar absorptivity coloration of coatings such as “brightwhite” paint, appliqués or matrix impregnation reduces the impact ofsolar heating. However, many applications for structural composites areenhanced by various coloration of the surface other than bright white.However, nearly half of the energy in the solar spectrum is in thevisible, so the solar absorptivity is very sensitive to visual color andintensity. Dark colors absorb almost all of the energy in the visibleband, and they usually absorb a high percentage of the solar energy inthe Near Infrared and UV as well, resulting in excessive heating of thesurfaces. To accommodate the additional thermal load due to solarheating, additional structural strength may be required which may impactweight and cost. Significant benefit has previously be obtained byspectrally tailoring the optical properties of a paint or coating, i.e.reflecting the UV and/or Near Infrared while allowing only the visibleabsorption (so that the desired colors are still possible) whilereducing the requirement for structural enhancement. This approach hasbeen used to design, scale up and manufacture a paint coating to reducethe thermal load on aircraft structures when the aircraft could not bewhite. Often greater reductions are needed than can be achieved bytailoring surface solar absorptivity alone.

Increasing fuel efficiency in modern aircraft is being accomplishedthrough improvement in aerodynamic performance and reduction ofstructural weight. Recent advances in the use of microstructures such asriblets on aerodynamic surfaces have shown significant promise inreducing drag to assist in reducing fuel usage. Riblets have variousforms but advantageous embodiments may be ridge-like structures thatminimize drag on the surface of an aircraft. Riblets may be used inareas of a surface of an aircraft where turbulent regions may bepresent. Riblets may limit circulation causing a breakup of large scalevortices in these turbulent regions near the surface in the boundarylayer to reduce drag. In certain tested applications riblets have beenpyramidal or inverted V shaped ridges spaced on the aerodynamic surfaceto extend along the surface in the direction of fluid flow. Ribletstructures have typically employed polymeric materials, typicallythermoplastic or thermoset polymers.

Surface appliqués for lightning protection, EMI shielding, P-staticmitigation and replacement of the decorative/protective paint are beingemployed on aircraft and other vehicles.

It would therefore be desirable for an appliqué with multiple functionsincluding reducing solar heating, aerodynamic drag reduction, lightningprotection, EMI shielding, P-static mitigation and paint replacement.

SUMMARY

Exemplary embodiments provide a reduced solar aborptivity appliquéhaving a surface layer for adhering to either a fixed structure such asa building or to an aerodynamic surface such as an aircraft, automobile,or wind turbine and riblet tips extending from the surface layer havingspectral tailoring. In certain embodiments, the spectral tailoring isaccomplished by colored pigmentation in the riblet tips. In alternativeembodiments the spectral tailoring may include such effects asabsorption in one portion of the solar spectrum, the ultraviolet (UV)and reemission at a different wavelength, in the visible or near IR asexamples. This can be done through the use of fluorescent molecules orpigments, phosphorescent molecules or quantum dots distributed in thematerial matrix of the riblet tips.

In certain configurations, the appliqué includes additional layers suchas a metallic layer, a polymer support layer and an adhesive layerapplied to the surface layer opposite the riblet tips. These additionallayers may be comparable to preexisting lightning strike appliqué s.Materials for the surface layer and riblet tips may include highelongation elastomers selected from the set of thermosetting orthermoplastic polymers urethane, epoxy fluoroelastomers, perfluoroether,fluorosilicone, polysulfide, silicones, EPDM elastomers, or othernon-elastomeric polymers of these same classes. In alternativeconfigurations, the riblet tips may be formed from such materials asnickel, chromium, metal alloys, glasses, or ceramics such as siliconcarbide or silicon nitride.

A cladding on the riblet tips may also be employed for spectraltailoring or for increased durability, for example to add a UV barrier.In one configuration, a cladding of quantum dots is an exampleembodiment.

Fabrication of a reduced solar absorptivity appliqué may be accomplishedby forming a complementary tool from a master tool to provide groovesand intermediate flat surfaces and depositing riblet tips havingspectral tailoring in the grooves of the complementary tool anddepositing a surface layer overlaying the tips and intermediate flatsurfaces of the complementary tool. An adhesive layer and other layerssuch as a metallic layer and polymer support layer may be deposited tofrom an appliqué. The appliqué is then removed from the complementarytool and adhered to an aerodynamic surface or may be adhered to theaircraft surface with the complementary tool in place and this tool isremoved at a later time.

A cladding for spectral tailoring may be deposited in the grooves of thecomplementary tool prior to deposition of the riblet tips.

The features, functions, and advantages that have been discussed can beachieved independently in various embodiments of the present inventionor may be combined in yet other embodiments further details of which canbe seen with reference to the following description and drawings

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is an isometric view of a portion of an aerodynamic surface suchas a wing or fuselage skin showing exemplary aerodynamic ribletsextending in the flow direction;

FIG. 1B is a top view of a portion of an aerodynamic surface employingriblets of the first embodiment as shown in FIG. 1A;

FIG. 1C is a section view comparable to FIG. 1A for reference with thefeatures of FIG. 1B;

FIG. 1D is a perspective view of an alternative embodiment of the highaspect ratio microstructures extending from the surface layer;

FIG. 2A is a section view of a multilayer appliqué embodiment;

FIG. 3 is a section view of a simplified embodiment with directadherence of the surface layer to the aerodynamic surface;

FIG. 4 is an isometric cutout of a vehicle surface with an appliqué ofthe embodiment of FIG. 2 installed;

FIG. 5A is a bar graph comparing temperatures on a typical surface forwhich the present embodiments would be employed with a bright whitesurface coating, colored paint and riblet appliqué;

FIG. 5B is a graph of reflectance for the representative riblet tipcoloration;

FIG. 5C is a graph showing relative heating rates for bright white,colored paints and riblet appliqués of varying colors;

FIG. 6 is a flow diagram of an exemplary process for fabricating amultilayer appliqué of the embodiment of FIG. 2;

FIG. 7 is a flow diagram of an alternative process for fabricating amultilayer appliqué of the embodiment of FIG. 2;

FIG. 8 is a flow diagram of a process for fabricating a multilayerappliqué of the embodiment of FIG. 3;

FIG. 9 is a flow chart of a method for creating riblet tips withspectral modification using quantum dots for the embodiments previouslydescribed;

FIG. 10A is a flow diagram describing use of the rigid tipped ribletsembodiments disclosed herein in the context of an aircraft manufacturingand service method; and

FIG. 10B is a block diagram representing an aircraft employing the rigidtipped riblets with embodiments as disclosed herein.

DETAILED DESCRIPTION

The embodiments disclosed herein provide high aspect ratio surfacemicrostructures such as aerodynamic riblets extending from a surfacelayer in an appliqué designed for reduced solar absorptivity whilemaintaining maximum durability. For exemplary purposes the embodimentsdisclosed herein are shown in use with aircraft as aerodynamic riblets.However, non-aircraft use of the described appliqués is equallyapplicable. The microstructures disclosed herein as exemplary ribletsmay be other shapes and patterns that are not typically used for dragreduction on airplanes. For example a three dimensional (3D) pattern ofprotrusions that block the direct view of the surface from the sun frommany angles, have minimal thermal contact area of the microstructure tipwith the flat surface, and/or provide spectrally tailored “tips” and“surfaces” to mitigate the solar absorption. For example, rows of bumpsof similar height and spacing as suggested for the riblets examplesprovided herein may be employed. For non-airplane applications, these 3Dstructures could be more advantageous because they can function the samefrom all azimuthal angles where the solar loading of the ridge/groovetype of riblet may be somewhat affected by the sun orientation relativeto the surface.

The appliqué may be multilayered to additionally provide one or moreconductive layers for lightning strike protection, EMI shielding andP-static migration. Reduced thermal loading of underlying structure isachieved by isolating the absorption and decorative color (whichconstitutes the primary solar absorber) into the riblet ridges, reducingthe heat transfer to the underlying appliqué and aircraft structure. Theriblets additionally enhance the ambient cooling by increasing surfacearea.

The embodiments disclosed herein may employ a parabolic sectionparticularly applicable for both high elongation elastomeric materialsand rigid materials for aerodynamic riblets that that may be impacted byground support equipment or environmental hazards such as hail toenhance deformation recovery and avoid permanent deformation/damage.These embodiments also allow an optimized structural design of ribletsproviding the capability for the riblets to be thinner and moreaerodynamically efficient. Non-elastomeric polymers as well as rigidmaterials including metals or ceramics with a small elastic region wouldnormally be deformed in a non-recoverable manner when a force is appliedto the riblet tip may more readily be employed with the parabolicsection.

An exemplary embodiment of riblets having a structure as will bedescribed in greater detail subsequently is shown as a portion of anaerodynamic surface for an aircraft as shown in FIG. 1A. The aircraft110 employs a structure with an aerodynamic surface 111, shown enlarged,having multiple substantially parallel riblets 112 arranged parallel tothe flow direction as represented by arrow 114. For the exemplaryembodiment shown in FIGS. 1B and 1C, the height dimension 116perpendicular to the surface 111 is approximately 0.002 to 0.05 inchwith a base of from 0.0004 to 0.010 inch with an aspect ratio of about 3to 6 or greater while the spacing 118 between the riblets isapproximately 0.003 inch. Spacing or distribution of the riblet tips 202protruding from a supporting surface layer 204 in an array may varydepending on and be predetermined by the desired thermal properties tobe obtained and, in a multifunction appliqué, the fluid dynamicproperties of the air, water or other fluid for which the application ofriblets is employed. Typically, a narrow base dimension 113 for theriblet tips 202 is desirable to reduce heat transfer from the riblet tothe surface layer 204. Returning to FIG. 1A, the aerodynamic surface istypically, without limitation, curved and may be a portion of a wing, anengine nacelle, a control surface, a fuselage or other suitable surface.Therefore flexibility and conformability of the riblets and anystructure supporting and affixing the riblets to the surface may berequired. While described herein with respect to an aircraft aerodynamicsurface the embodiments disclosed herein are equally applicable for dragreduction on surfaces of other aerospace vehicles such as, withoutlimitation, missiles or rockets and other vehicles such as cars, trucks,buses and trains which employ composite structures or otherwise requirereduced solar absorptivity for thermal performance enhancement.

As previously described, alternative microstructural shapes may beemployed. FIG. 1D shows an alternative form for the protrudingmicrostructural tips 202′ extending from the surface layer 204.

The embodiments disclosed herein recognize and provide the capabilityfor riblets that may resist various impacts and/or other forces that mayreduce riblet durability. Further, certain of the different advantageousembodiments provide a multi-layer structure that may have a surfacelayer 204 and a plurality of riblet tips 202 located on or extendingfrom the supporting surface layer. In exemplary embodiments described indetail subsequently, the structures which form the riblets may befabricated from high elongation elastomeric materials. The embodimentsshown are also applicable for rigid tipped riblets or shape memoryriblets for additional structural capability.

An embodiment for an appliqué with reduced solar absorptivity riblets isshown in FIG. 2 as a multilayer construction. Individual tips 202 of theriblets, protrude from surface layer 204. A multilayer structureincorporating a screen and/or foil metallic layer 206 such as aluminum,a polymer support layer 208 and an adhesive layer 210 supports thesurface layer 204. The polymer support layer 208 and adhesive layer 210,with or without the metallic layer 206 may be supplied as a portion of apreformed appliqué or directly deposited on the surface layer 204 aswill be described in greater detail subsequently. The metallic layer 206provides a conducting material for lightning strike protection in anexemplary aircraft usage of the embodiment. The metallic, polymersupport and adhesive multilayer structure may be comparable to a currentlightning strike appliqué (LSA) employed for composite aircraftstructural surfaces.

For an exemplary configuration for the embodiment shown in FIG. 2, thesurface layer 204 is approximately 2 mils in thickness and has a brightwhite coloration. The riblet tips 202 are approximately 2 mils in heightand spaced approximately 3 mils apart consistent with exemplaryrequirements for an aerodynamic riblet appliqué. The riblet tips containthe sole coloration, in the embodiment shown a red pigmentation. Thecolored riblet surfaces are created by ink, dyes or pigmentation of theriblet polymer or surface coating using pigmentation selected for lightfastness as well as color (absorptivity in the visible spectrum) and forlack of absorptivity in the near infrared and near ultraviolet (UV).Example pigments are inorganics such as iron oxide yellow and manyorganics including perylene black such as BASF Euvinyl C Black 00-8702;perylene reds such as Pigment Red 179 (Perrindo Maroon 179) from SunChemical; Pigment Red 178 from BASF; Sandorin Reds and Oranges;Toluidine Red (Pigment Red 3); Diazo Condensation Pigments such asPigment Red 165-166 or 220-221 or Pigment Yellow 93-95 or 128;Quinacridone pigments such as Pigment Red 202 or violet 19); CarbazoleDioxazine Violet; Benzimidazolone pigments; Alizarine Lake Reds;Permanent Red; Lithol Red (Pigment Red 49); Anthraquinone pigments; orblue or green phthalocyanine pigments for example copper phthalocyaninefrom suppliers such as BASF (Euvinyl C Blue 69-0202). Stable yelloworganics transparent in the near infrared are also available, forexample Sandorin Yellows; or Hansa or other Diarylide Yellows (Pigmentyellow 1, 3, 65, 73, 74, 75, 97, 98) or oranges; Isolindoline-basedpigments such as Pigment Orange 66; or Pigment Yellow 139 (PaliotolYellow L 1820 from BASF); and tetrachloroisoindolinone-based pigmentssuch as Pigment Yellow 110. Alternatively, the coloring material may beabsorptive in the visible regions of interest and reflective in the nearinfrared or UV due to scattering (a result of the particulate size andhigh index of refraction). Example of pigments that are absorptive inthe visible but reflective in the near infrared are chromium oxide(Pigment Green 17; lead chrome (Pigment Yellow 34, Pigment Red 104,Pigment Orange 21; Molybdate Orange (Pigment Red 104); cadmium sulfidepigments such as Pigment Yellow 37, Pigment Orange 20 and Pigment Red108; a select set of mixed metal oxide pigments for example chrometitanate yellow; and bismuth vanadate/molybdate pigments (Pigment Yellow184).

For the embodiment shown in FIG. 2 the surface layer 204 may be selectedfrom various polymers pigmented with materials such as inks, elastomersincluding polyurethanes, polyureas, polysulfides, epoxy-basedelastomers, silicones, fluoroelastomers such as perfluoroether,fluorosilicones, EPDM elastomers, or from non-elastomeric polymersincluding thermosets and thermoplastics including materials such aspolyurethanes, polyureas, epoxy, fluorinated polymers such asfluorinated ethylene propylene (FEP), polyolefins, polyetheretherketone(PEEK), Polyetherketoneketone (PEKK) or polyamide. The surface layer maybe transparent with an underlying white or bright metallic reflectorsuch as aluminum. The white surface is typically generated by ink, dyesor pigmentation of the surface polymer using bright white pigments suchas titanium dioxide, zinc oxide, zinc sulfide, antimony oxide, zirconiumoxide or other particulate with a high index of refraction and a sizerange that maximizes reflection in the UV, visible and near infrared,typically 0.1-0.5 micrometers. The riblet tips 202 may be of variousmaterials including polymers identical to or comparable to thosedescribed and used on the surface layer 204. For certain of theembodiments herein the riblets may be made of an elastomer or a veryhigh modulus material, however the surface layer may actually providebetter overall performance if it is not an elastomer. These polymers maybe loaded during casting with the desired pigmentation as describedabove. Alternatively, the riblet tips 202 may employ glass, ceramics,chromium, other metal alloys, silicon carbide or silicon nitride whichmay be treated to provide the desired coloration or naturally provide acoloration effect. While silicon carbide and nitride will be quite darksuch properties may be desirable for certain applications. The adhesivelayer 210 may be one of many possibilities including, withoutlimitation, pressure sensitive acrylic adhesives, polyurethane pressuresensitive adhesives, polysulfide, epoxy, thermoplastics,thermally-reactive adhesives, silicone adhesives, or fluorosiliconeadhesives. The polymer support layer 208 may be a single layer ormultiple layers fabricated from polyetheretherketone (PEEK), polyamide,polyester, polyolefin or similar polymer film.

In alternative embodiments, various layers of the embodiment shown inFIG. 2 may be eliminated depending on the intended application. In asimple form, an appliqué 300 may be formed solely by the surface layer204 and riblet tips 202 as shown in FIG. 3. The surface layer may employa thermoplastic which may be directly adhered to the aircraft surface.FIG. 3 additionally shows the use of a parabolic profile for the ribletsproviding improved structural capability as disclosed in co-pending U.S.patent application Ser. No. 12/566,907 filed on Sep. 25, 2009 entitledStructurally Designed Aerodynamic Riblets.

Additionally, the surface layer in the embodiments described previouslymay be spectrally tailored as well with pigments or processes asdescribed for the riblet tips. Spectral tailoring of the surface layermay provide low solar absorption/high solar reflection and may or maynot be the same color as the riblet tip for decorative purposes or toenhance overall performance. The surface layer may be bright white or abright metallic as previously described or could be a transparent layerwith a white or other bright reflector present on a lower layer such asa metallic layer in the appliqué or on the surface to which the ribletappliqué is attached. As will be described subsequently, quantum dotsthat absorb UV and emit in the visible or near infrared may also beapplied to the surface layer or surface claddings applied in a mannersimilar to the riblets.

Analysis of the exemplary appliqué configuration of FIG. 2 shown insection as applied to a composite fiber reinforced polymer (CFRP)aircraft structural skin 402 formed of BMS8-276 as shown in FIG. 4 hasbeen conducted for a normal solar spectral radiance with approximately7% Ultraviolet, 47% visible and 46% near Infrared radiation componentsand employing an exemplary 45 degree angle of incidence for solarradiation 404. As shown in FIG. 5A, a 21-degree F. reduction in thecomposite skin surface temperature to 196 F, bar 502, due to thepresence of the multicolored riblet as compared to a conventional colorcoating of the same dark color which would have a surface temperature of217 F, bar 504. A bright white coating would have a temperature of 131F, bar 506. No special tailoring of UV, Visible or Near IR absorptionwas included for the exemplary analysis of FIG. 5A. The resultingspectral reflectance 508 of the exemplary riblets is shown in FIG. 5B.The riblet tips can be pigmented using a combination of pigments thatprovide the desired visual color (in this case red, showing a relativeincrease in the reflectivity, portion 510, in the red part of thevisible spectrum) while maximizing the reflection or minimizing theabsorption in the Near Infrared and UV. In the example embodimentdescribed, perylene reds such as Pigment Red 179 (Perrindo Maroon 179)from Sun Chemical or Pigment Red 178 from BASF are employed. However,alternative colors/pigments as described above may be employed. UVreflections can be increased by the selection of less typical coatingelements, as will be described in greater detail subsequently, andspectral tailoring of the riblet to reduce the solar band absorptionsprovides additional temperature reductions in a skin employing a ribletappliqué.

In the graph in FIG. 5C, arrow 512 shows the solar absorptivity for abright white surface, arrow 514 the absorptivity for a light graysurface and arrows 516 and 518 for blue and red surfaces as exemplary ofdark colors. The typical heating ranges for the various colors are shownby the associated dashed lines 520, 522 and 524 respectively. Thetemperatures in FIG. 5C are steady state values calculated assuming a130 F ambient temperature and a convection coefficient of 0.25Btu/ft²-hr-F representing natural convection. A solar radiative heatflux of 1120 W/m² with a 45 deg incidence angle is also applied to theriblets and surface layer/skin. Solid line 526 represents the exemplaryheating for a riblet appliqué created with colors having solarabsorptivity corresponding to the ordinate values. The solarabsorptivity of the riblet tips will determine what the maximum hot daytemperature would be for an exemplary CFRP skin as represented by theabscissa value for line 526.

An exemplary process for creation of an appliqué as described for theembodiment in FIG. 2 is shown in FIG. 6. A web tool 602 is created instep 640 by impression on a master tool (not shown) which providesgrooves 604 corresponding to the riblet shape. Spacing between thegrooves provides a substantially flat intermediate surface 606corresponding to the dimension 118 desired between the riblets 112 aspreviously discussed with respect to FIG. 1. A resist layer 608 isapplied to the intermediate flat surfaces 606 in step 642. Riblet tips202 with pigmented coloring or other spectral modification are then castinto the web tool 602 in step 644. The resist layer 608 preventsadherence of the elastomer or other casting material of the coloredriblet tips to the intermediate flat surfaces to provide distinct riblettips. In step 646 the resist, and any excess material prevented by theresist from adhering to the intermediate flat surfaces is removed with awash. For the embodiment shown bases 610 of the riblet material areplaced into relief extending from the tool by the casting over theresist. In alternative embodiments depending on riblet tip and surfacelayer materials and techniques for adherence of the riblet tips to thesurface layer, the riblet bases may be flush with the intermediate flatsurfaces 606. The surface layer 204 is then cast over the riblet tips202 in step 646.

For the exemplary process shown with respect to FIG. 6 a preformedappliqué 612 incorporating the multilayer structure of aluminum foil asa metallic layer 206, polymer layer 208 and adhesive layer 210 isadhered to the cast surface layer in step 648. A removable adhesiveliner 614 for preservation of the adhesive during further processing isshown. The completed multilayer appliqué 616 may then be applied to anairplane surface 111 by removing the adhesive liner 614 and adhering theadhesive layer 210 to the surface 111 as shown in step 650.

An alternative process for creation of an appliqué as described for theembodiment in FIG. 2 is shown in FIG. 7. A web tool 702 is created instep 740 as previously discussed with respect to FIG. 6 with grooves 704and intermediate surfaces 706. A resist layer 708 is applied to theintermediate flat surfaces 706 in step 742. A cladding 720 is cast,sputtered or formed into the grooves 704 in step 744 with the resistlayer 708 preventing adherence to the intermediate flat surfaces. Thecladding may include one or more layers to provide coloration for theriblet tips or other decorative appearance through the creation ofinterference colors. Exemplary cladding may be thin film conformalcoatings incorporating inorganic, organic or polymeric matrices. Organicor inorganic additives/fillers for example inks or dip coating solutionsmay be included in the cladding or they may be a wide range of singleand multilayered cladding that can be applied by surface modification,sputtering, physical deposition such as vapor or plasma deposition orchemical vapor depositions. Materials deposited include metals such asaluminum, gold indium, tin and chromium; oxides of metals;semiconductors such as tin oxide, cadmium stannate, or antimony sulfide;or they may be organics/polymers such as perylenes, porphyrins,phthalocyanines, fluoropolymers or organometallics. The cladding may beelectrodeposited materials including metals and metal oxides orconductive polymers; or those cladding deposited by electrophoresis insingle or multilayers for example nanolayered metals, polymers andoxides deposited by Modumental. The cladding may be used as additionalcoloration or decorative effects with coloration in the riblet tipmaterial as well or as the sole source of coloration. Coatings such asquantum dots may be employed for additional spectral tailoring as willbe described subsequently. Riblet tips 202 are then cast into the webtool 702 in step 746. The resist layer 708 prevents adherence of theelastomer or other casting material of the riblet tips to theintermediate flat surfaces to provide distinct riblet tips. In step 748the resist is removed. For the embodiment shown bases 710 of the ribletmaterial are placed into relief extending from the tool by the castingover the resist. In alternative embodiments depending on riblet tip andsurface layer materials and techniques for adherence of the riblet tipsto the surface layer, the riblet bases are flush with the intermediateflat surfaces. The surface layer 204 is then cast over the riblet tips202 in step 750.

For embodiments where coloration is obtained solely from the claddingand the material for the riblet tips and the surface layer are the same,the riblet tips and surface layer may be deposited onto the tool in twosteps without the use of a resist. Thin multilayered conformal thin filmcoatings are done routinely by various deposition processes such assputtering or spray coating either in batch operations or viaroll-to-roll processing where one coating (for the cladding) is appliedfollowed immediately down stream (or in a separate processing step) bythe application of the second layer (the riblet tip) followed by theapplication of the third layer (surface layer).

For the exemplary process shown with respect to FIG. 7 a preformedappliqué 712 incorporating the multilayer structure of aluminum foil asa metallic layer 206, polymer layer 208 and adhesive layer 210 isadhered to the cast surface layer in step 752. A removable adhesiveliner 714 for preservation of the adhesive during further processing isshown. The completed multilayer appliqué 716 may then be applied to anairplane surface 111 by removing the adhesive liner 614 and adhering theadhesive layer 210 to the surface 111 as shown in step 650.

An exemplary process for creation of an appliqué as described for theembodiment in FIG. 3 is shown in FIG. 8. A web tool 802 is created instep 840 by impression on a master tool (not shown) which providesgrooves 804 corresponding to the riblet shape. Spacing between thegrooves provides a substantially flat intermediate surface 806corresponding to the dimension 118 desired between the riblets 112 aspreviously discussed with respect to FIG. 1. A resist layer 808 isapplied to the intermediate flat surfaces 806 in step 842. Riblet tips202 with pigmented coloring or other coloring or spectral modificationare then cast into the web tool 802 in step 844. The resist layer 808prevents adherence of the elastomer or other casting material of thecolored riblet tips to the intermediate flat surfaces to providedistinct riblet tips. In step 846 the resist is removed. For theembodiment shown the cast riblets are flush with the intermediate flatsurface portions. A thermally-reactive or thermoplastic surface layer204 is then cast or laminated over the riblet tips 202 in step 846.

In alternative embodiments, the colored riblet 202 may be formed withoutresist by casting for example, so that the colored riblet tips are“filled” or nearly filled and the intermediate flat surfaces 806 are notcoated (for example where a blade is drawn along the surface of thetooling and the riblet tips are filled while the flat surfaces are wipedclean) This can be accomplished in a single roll coating run withmultiple coating stations where the riblets are cast and dried/partiallycured followed by the application of the white surface layer 204 at thesecond coating station.

The completed appliqué 816 may then be applied to an airplane surface111 by pressure and heating the material of the surface layer 204 andadhering it to the surface 111 as shown in step 848.

As previously discussed, tailoring of spectral reflection properties ofthe riblets in addition to coloration may be accomplished to furtherreduce heating of the surface. In one embodiment, the spectral tailoringmay be enhanced through the use of mutilayered thin film cladding on theriblet surfaces by processes such as sputtering. These multilayeredcoatings may form interference layers that allow the design of thedesired color in the visible with high reflectivity in the near infraredand/or UV. In another exemplary embodiment described in FIG. 9, Quantumdots are grown to provide for spectral tailoring with a reduced heatload (absorbing UV for example but also reemitting in the visible ornear IR), step 902. The quantum dots are then distributed into theriblet tips by either mixing into the base material for casting theriblets to distribute the quantum dots into the matrix of the riblet tipmaterial, step 904, to create an embodiment similar to that describedfor the process of FIG. 6 or by a thin film conformal coating on top ofthe preformed riblets or by depositing the quantum dots into a web toolas a cladding, step 906, to create an embodiment similar to thatdescribed for the process of FIG. 7. The riblet tip material is thendeposited or formed in the grooves of the tool, step 908, and thesurface layer deposited onto the intermediate flat surfaces, step 910.If coloration or spectral tailoring of the riblet tips is accomplishedexclusively by the quantum dots and the riblet tips and surface layerare a common material, the deposition of the riblet tips and surfacelayer may be accomplished as a single step. Surfactants or pendantorganic moieties on the quantum dots may also be used to preferentiallyarrange the quantum dots near the riblet tool surfaces allowing thecladding and riblet casting to be performed in a single step. Anyadditional layers to create an appliqué are then deposited on or appliedto the surface layer, step 912 and the appliqué is then adhered to thestructural surface, step 914.

Referring more particularly to FIGS. 10A and 10B, embodiments of thehigh elongation elastomeric or rigid-tipped riblets disclosed herein andthe methods for their fabrication may be described in the context of anaircraft manufacturing and service method 1000 as shown in FIG. 10A andan aircraft 1002 as shown in FIG. 10B. During pre-production, exemplarymethod 1000 may include specification and design 1004 of the aircraftand material procurement 1006. During production, component andsubassembly manufacturing 1008 and system integration 1010 of theaircraft takes place. The riblet appliqués and their manufacturingprocesses as described herein may be accomplished as a portion of theproduction, component and subassembly manufacturing step 1008 and/or asa portion of the system integration 1010. Thereafter, the aircraft maygo through certification and delivery 1012 in order to be placed inservice 1014. While in service by a customer, the aircraft 1002 isscheduled for routine maintenance and service 1016 (which may alsoinclude modification, reconfiguration, refurbishment, and so on). Theriblet appliqués as described herein may also be fabricated and appliedas a portion of routine maintenance and service 1016.

Each of the processes of method 1000 may be performed or carried out bya system integrator, a third party, and/or an operator (e.g., acustomer). For the purposes of this description, a system integrator mayinclude without limitation any number of aircraft manufacturers andmajor-system subcontractors; a third party may include withoutlimitation any number of venders, subcontractors, and suppliers; and anoperator may be an airline, leasing company, military entity, serviceorganization, and so on.

As shown in FIG. 10B, the aircraft 1002 produced by exemplary method1000 may include an airframe 1018 having a surface 111 as described withrespect to FIG. 1 and a plurality of systems 1020 and an interior 1022.Examples of high-level systems 1020 include one or more of a propulsionsystems 1024, an electrical and avionics system 1026, a hydraulic system1028, and an environmental system 1030. Any number of other systems maybe included. The high elongation elastomeric or rigid-tipped ribletssupported by the embodiments disclosed herein may be a portion of theairframe 1018, notably the finishing of skin and exterior surfaces.Although an aerospace example is shown, the principles disclosed in theembodiments aerodynamic riblet appliqués herein may be applied to otherindustries, such as the automotive industry, wind power generationindustry and the marine/ship industry.

Apparatus and methods embodied herein may be employed during any one ormore of the stages of the production and service method 1000. Forexample, components or subassemblies corresponding to production process1008 may be fabricated or manufactured in a manner similar to componentsor subassemblies produced while the aircraft 1002 is in service. Also,one or more apparatus embodiments, method embodiments, or a combinationthereof may be utilized during the production stages 1008 and 1010, forexample, by substantially expediting assembly of or reducing the cost ofan aircraft 1002. Similarly, one or more of apparatus embodiments,method embodiments, or a combination thereof may be utilized while theaircraft 1002 is in service, for example and without limitation, tomaintenance and service 1016.

Having now described various embodiments in detail as required by thepatent statutes, those skilled in the art will recognize modificationsand substitutions to the specific embodiments disclosed herein. Suchmodifications are within the scope and intent of the present disclosureas defined in the following claims.

What is claimed is:
 1. A reduced solar absorptivity appliqué comprising:a surface layer for adhering to a surface and having bright whitecoloration; a plurality of high aspect ratio microstructures extendingfrom the surface layer with spectral tailoring present solely in themicrostructures.
 2. The reduced solar absorptivity appliqué as definedin claim 1 wherein the spectral tailoring comprises decorativecoloration.
 3. The reduced solar absorptivity appliqué as defined inclaim 1 wherein the spectral tailoring of the microstructures absorbsselected wavelengths of visible radiation and reflects radiation in UVand near IR wavelengths.
 4. The reduced solar absorptivity appliqué asdefined in claim 1 further comprising a cladding on the microstructures.5. The reduced solar absorptivity appliqué as defined in claim 4 whereinthe cladding is selected from the set of organic or inorganicadditives/fillers including inks and dip coating solutions, single andmultilayered coatings applied by surface modification, sputtering,physical deposition including vapor deposition, plasma deposition andchemical vapor depositions wherein said materials deposited includemetals such as aluminum, gold, indium, tin and chromium, oxides ofmetals, and organics/polymers including perylenes, porphyrins,phthalocyanines, fluoropolymers or organometallics, electrodepositedmaterials including metals and metal oxides or conductive polymers,coatings deposited by electrophoresis in single or multilayers includingnanolayered metals, polymers and oxides.
 6. The reduced solarabsorptivity appliqué as defined in claim 1 further comprising a polymersupport layer deposited on the surface layer opposite themicrostructures.
 7. The reduced solar absorptivity appliqué as definedin claim 6 further comprising an adhesive layer deposited on the polymersupport layer to form a multilayer appliqué, said adhesive layeradhering the appliqué to a surface.
 8. The reduced solar absorptivityappliqué as defined in claim 2 wherein the microstructures and thesurface layer comprise a high elongation elastomer and furthercomprising a spectral tailoring cladding on the microstructures.
 9. Thereduced solar absorptivity appliqué as defined in claim 1 wherein themicrostructures are formed from material selected from the set of highelongation elastomers, metals, metal alloys selected from the set ofcrystalline or amorphous glass alloys, ceramics selected from the set ofcrystalline ceramics including Silicon Carbide or Silicon Nitride oramorphous ceramics including borosilicate glass.
 10. The reduced solarabsorptivity appliqué as defined in claim 1 further comprising ametallic layer, a polymer support layer and an adhesive layer applied tothe surface layer opposite the microstructures.
 11. The reduced solarabsorptivity appliqué as defined in claim 1 wherein the microstructuresare loaded with pigmentation.
 12. The reduced solar absorptivityappliqué as defined in claim 9 wherein the spectral tailoring comprisespigmentation selected from the set of organics including perylene black,perylene reds, blue and green phthalocyanine pigments and stable yelloworganics transparent in the near infrared.
 13. The reduced solarabsorptivity appliqué as defined in claim 1 wherein the spectraltailoring comprises materials incorporated in a material matrix in themicrostructures absorbing UV radiation and reemitting at a differentwavelength in a visible spectrum.
 14. The reduced solar absorptivityappliqué as defined in claim 1 wherein the spectral tailoring comprisesmaterials incorporated in a material matrix in the microstructuresabsorbing UV radiation and reemitting at a different wavelength in anear IR spectrum.
 15. The reduced solar absorptivity appliqué as definedin claim 13 wherein the materials incorporated in the material matrix inthe microstructure are selected from the set of fluorescent molecules,flourescent pigments and phosphorescent molecules.
 16. The reduced solarabsorptivity appliqué as defined in claim 13 wherein the materialsincorporated in the material matrix in the microstructure are quantumdots.
 17. The reduced solar absorptivity appliqué as defined in claim 4wherein the spectral tailoring comprises materials incorporated in thecladding absorbing UV radiation and reemitting at a different wavelengthin a near IR spectrum.
 18. The reduced solar absorptivity appliqué asdefined in claim 17 wherein the cladding comprises quantum dots.